I have set up a number of custom box sizes with outside and inside dimensions, box weight, max weight values. I have products with specified dimensions that are smaller than the inside dimensions for their intended box. In some cases, multiple items should be packaged together.

However, when I click the ‘Generate Packages’ button, the results are not at all logical. Each items is being packaged into it’s own box, even when they can be combined. Additionally, the weights generated are wildly wrong.

For example, a customer orders the following products:
SomeLargeProduct, 25.0 lbs, 66×8×8 in, Quantity 1
SomeSmallProduct, 2.0 lbs, 18×13×2.5 in, Quantity 2

Among the boxes I have enabled, these are the best fit:
Box measuring 69×9×9 inches, weighing 4.0 lbs
Box measuring 20×16×7 inches, weighing 1.16 lbs

Here’s how I’d expect the products to be packaged:
Package 1 69×9×9 inches, 29 lbs
Package 2 20×14×7 inches, 5.16 lbs

Instead, here’s how they are being packaged:
Package 1 69×9×9 inches 34.17 lbs
Package 2 20×14×7 inches 31.16 lbs
Package 3 20×14×7 inches 31.16 lbs

While I can manually edit the incorrect weights, I cannot remove the redundant package (The two SomeSmallProducts could fit together in a single box). Any idea why this would happen and how I might correct it?

Thanks!